Owner s Manual For Thern Worm Gear Hand Winches ORIGINAL TEXT

Read this Owner s Manual thoroughly before operating the equipment. Keep it with the equipment at all times. Replacements are available from Thern, Inc., PO Box 347, Winona, MN 55987, 507-454-2996. www.thern.com IMPORTANT: Please record product information on page 2. This information is required when calling the factory for service. ORIGINAL TEXT Owner s Manual For Thern Worm Gear Hand Winches

page 2 Owner's Manual for Thern Worm Gear Hand Winches Two-Year Limited Warranty Please record the following: Date Purchased: Model No.: Code No.: This information is required when calling the factory for service. Thern, Inc. warrants its products against defects in material or workmanship for two years from the date of purchase by the original using buyer, or if this date cannot be established, the date the product was sold by Thern, Inc. to the dealer. To make a claim under this warranty, contact the factory for an RGA number. The product must be returned, prepaid, directly to Thern, Inc., 5712 Industrial Park Road, Winona, Minnesota 55987. The following information must accompany the product: the RGA number, the date of purchase, the description of the claimed defect, and a complete explanation of the circumstances involved. If the product is found to be defective, it will be repaired or replaced free of charge, and Thern, Inc. will reimburse the shipping cost within the contiguous USA. This warranty does not cover any damage due to accident, misuse, abuse, or negligence. Any alteration, repair or modification of the product outside the Thern, Inc. factory shall void this warranty. This warranty does not cover any costs for removal of our product, downtime, or any other incidental or consequential costs or damages resulting from the claimed defects. This warranty does not cover brake discs, wire rope or other wear components, as their life is subject to use conditions which vary between applications. FACTORY AUTHORIZED REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY TO THE CONSUMER. THERN, INC. SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON THIS PRODUCT. EXCEPT TO THE EXTENT PROHIBITED BY APPLICABLE LAW, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ON THIS PRODUCT IS LIMITED IN DURATION TO THE DURATION OF THIS WARRANTY. Some states do not allow the exclusion or limitation of incidental or consequential damages, or allow limitations on how long an implied warranty lasts, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Note: Thern, Inc. reserves the right to change the design or discontinue the production of any product without prior notice. About This Manual The Occupational Safety and Health Act of 1970 states that it is the employer s responsibility to provide a workplace free of hazard. To this end, all equipment should be installed, operated, and maintained in compliance with applicable trade, industrial, federal, state, and local regulations. It is the equipment owner's responsibility to obtain copies of these regulations and to determine the suitability of the equipment to its intended use. This Owner s Manual, and warning labels attached to the equipment, are to serve as guidelines for hazard-free installation, operation, and maintenance. They should not be understood to prepare you for every possible situation. The information contained in this manual is applicable only to the Thern Worm Gear Hand Winches. Do not use this manual as a source of information for any other equipment. The following symbols are used for emphasis throughout this manual: Failure to follow WARNING! instructions may result in equipment damage, property damage, and/or serious personal injury. Failure to follow CAUTION! instructions may result in equipment damage, property damage, and/or minor personal injury. Important! Failure to follow important! instructions may result in poor performance of the equipment.

Owner's Manual for Thern Worm Gear Hand Winches page 3 Suggestions for Safe Operation DO the following: Read and comply with the guidelines set forth in this Owner s Manual. Keep this manual, and all labels attached to the winch, readable and with the equipment at all times. Contact Thern, Inc. for replacements. Check lubrication before use. Install the wire rope securely to the winch drum. Keep at least 4 wraps of wire rope wound on the drum at all times, to serve as anchor wraps. With less than 4 wraps on the drum the wire rope could come loose, causing the load to escape. Keep hands away from the drum, gears, wire rope, and other moving parts of the equipment. Keep all unnecessary personnel away from winch while in operation. Keep out of the path of the load, and out of the path of a broken wire rope that might snap back and cause injury. DO NOT do the following: Do not lift people, or things over people. Do not walk or work under a load or in the line of force of any load. Do not exceed the load rating of the winch or any other component in the system. To do so could result in failure of the equipment. Do not use more than one winch to move a load that unless each winch was designed for use in a multiple winch system. Do not use damaged or malfunctioning equipment. To do so could result in failure of the equipment. Do not modify the equipment in any way. To do so could cause equipment failure. Do not wrap the wire rope around the load. This damages the wire rope and could cause the load to escape. Use approved rigging connectors to secure the wire rope to the load. Do not lift loads or pull loads on an incline unless the winch is equipped with a brake. Do not divert your attention from the operation. Stay alert to the possibility of accidents, and try to prevent them from happening. Do not jerk or swing the load. Avoid shock loads by starting and stopping the load smoothly. Shock loads overload the equipment and may cause damage. Do not leave a suspended load unattended unless specific precautions have been taken to secure the load and keep people away from the winch and out from under the load.

page 4 Owner's Manual for Thern Worm Gear Hand Winches 1.1 Installing the Winch Important! Inspect the winch immediately following installation according to the Instructions for Periodic Inspection. This will give you a record of the condition of the winch with which to compare future inspections. A qualified professional should inspect or design the foundation to insure that it will provide adequate support. Locate the winch so it will be visible during the entire operation. Do not weld the winch frame to the foundation or support structure. Welding the frame may void warranty, contact Thern, Inc. Use fasteners as instructed. Do not install the winch in an area defined as hazardous by the National Electric Code, unless installation in such an area has been thoroughly approved. Do not install the winch near corrosive chemicals, flammable materials, explosives, or other elements that may damage the winch or injure the operator. Adequately protect the winch and the operator from such elements. Position the winch so the operator can stand clear of the load, and out of the path of a broken wire rope that could snap back and cause injury. Attach the winch to a rigid and level foundation that will support the winch and its load under all load conditions, including shock loading. 1.1.1 Consult applicable codes and regulations for specific rules on installing the equipment. 1.1.2 Locate the winch in an area clear of traffic and obstacles. Make sure winch is accessible for maintenance and operation. 1.1.3 POSITION THE WINCH HORIZONTALLY to in sure proper lubrication. Do not in stall the winch vertically or up side-down, unless it has been modified for this type of installation. To convert the winch for vertical installation, remove the four bolts holding the gear case to the frame, turn the frame 90, and re in stall the bolts. See Figure 1. 1.1.4 Maintain a fleet angle between 1/2 and 1-1/2 degrees. The proper fleet angle minimizes wire rope damage by helping the wire rope wind uniformly onto the drum. See Figure 2. 1.1.5 position the winch to allow access for proper lubrication. 1.1.6 Fasten the winch securely to the foundation. a FOR STANDARD PRODUCTS referred to in this manual, use 3/8 inch coarse thread fasteners, grade 5 or better, torqued dry to 30 ft-lbs without lubrication for Models 462 and 4622PB. Use 1/2 inch coarse thread fasteners, grade 5 or better, torqued dry to 75 ft-lbs without lubrication for Models 472, 4722PB, 482 and 482B. Make sure the winch frame is secured to a solid foundation able to support the winch and the load under all conditions with design factors based on accepted engineering practices. b Non-standard products that vary from the original design may have different fastening requirements. Contact a structural engineer or Thern, Inc. for this information. TO COMPLY WITH LOCAL CODES, CONTACT A QUALIFIED PROFESSIONAL TO OBTAIN PROPER STRUCTURE OR FOUNDATION SPECIFICATIONS FOR THE MOUNTING OF THERN PRODUCTS.

Owner's Manual for Thern Worm Gear Hand Winches page 5 1.2 Installing the Breather Plug Check if a breather plug is installed to vent heat and pressure from the gearbox. Failure to do so could result in pressure buildup which can cause the gearbox to leak or damage the equipment. Breather plugs are required for the PB series. Refer to the parts list for your model. This winch is shipped sealed with a plug and without lubricant in the gearbox. 1.2.1 install the breather plug in the proper location. Make sure the breather plug is above the lubricant level. See Figure 1. 1.2.2 CHECK LUBRICANT LEVEL in the gearbox before operating. Refer to section 3.2 - Lubricating the Winch. Figure 1 Installing the Breather Plug breather plug breather plug breather plug floor mount wall mount ceiling mount Important! Use a sheave or roller guide to direct the wire rope to the drum whenever possible. Install sheaves, tracks and other equipment so they will remain fixed under all load conditions. Follow the recommendations of the equipment manufacturer. Use sheaves of proper diameter to minimize wear on the wire rope. Follow the recommendations of the sheave manufacturer. Figure 2 Maintaining the Fleet Angle When wire rope travels over a sheave or through a roller guide maintain fleet angle by locating the sheave or guide an appropriate distance from the drum, shown as distance A. fixed sheave or roller guide smooth drum 1/2 to 1-1/2 degrees distance A center line When wire rope travels directly to the load maintain fleet angle by controlling sideto-side movement of the load with tracks or guide rails. Allowing the load to move too far to one side causes stress on the drum flange which may cause damage. load smooth drum 1/2 to 1-1/2 degrees center line tracks or guide rails

page 6 Owner's Manual for Thern Worm Gear Hand Winches 1.3 Installing the Handle Figure 3 Handle Adjustment larger turning radius: heavier loads, slower turns smaller turning radius: lighter loads, faster turns cotter pin bend arms back 1.3.1 for models 462, 472, 482 and 482b, install the handle as follows, see Figure 3. a b insert the handle in the handle socket, adjust handle length to suit the operation, and tighten the set screw to hold it in place. insert the cotter pin in the end of the handle and bend the arms back to secure in place. 1.3.2 for models 4622pb and 4722pb equipped with PB brakes, install the handle as follows: a b c d loosen the thumbscrew and slide the handle toward the medallion as shown. See Figure 4A. line up the notch in the handle with the point of the hex in the medallion. See Figure 4B. slide the handle and medallion assembly onto the hex drive on the brake until the flat of the handle lines up with the groove in the hex drive. See Figure 4C. slide the handle outward away from the medallion to the desired length and tighten the thumbscrew. See Figure 3B. Figure 4 Installing the Handle 4A 4B loosen thumbscrew and slide handle in direction shown slide thumbscrew line up notch with point of hex in medallion notch medallion notch 4C 4D slide handle out to desired length and tighten thumbscrew groove slide handle assembly onto hex drive until handle flat lines up with groove slide thumbscrew

Owner's Manual for Thern Worm Gear Hand Winches page 7 1.4 Installing the Wire Rope Important! Use wire rope and other rigging equipment rated for the size of the largest load you will be moving. Do not drag the wire rope through dirt or debris that could cause damage, or poor operation. Always wear protective clothing when handling wire rope. Install the wire rope securely to the winch drum. A poorly secured wire rope could come loose from its anchor and allow the load to escape. Install the wire rope so it is wound correctly, as shown, or the winch and brake will not work properly, and could allow the load the escape, see Figures 5 and 6. 1.4.1 Purchase the proper wire rope for your application. Keep the following in mind when selecting a wire rope. Contact a reputable wire rope supplier for help. a b c Breaking strength of new wire rope should be at least 3 times greater than the largest load placed on the winch. If loads are lifted or pulled on an incline, the breaking strength must be at least 5 times greater than the largest load. These are minimum values and will vary with the type of load and how you are moving it. Wire rope lay must agree with the winding direction of the drum to help insure proper winding. We recommend 7 x 19 galvanized aircraft cable for diameters up to 5/16 inch, and 6 x 37 IWRC improved plow steel wire rope for diameters of 3/8 inch and up. 1.4.2 for models 462 and 4622pb anchor the wire rope using the cable anchor. See Figure 5. a b c loosen the anchor bolt and place the wire rope between the drum flange and the bolt. wrap the wire rope around the drum one time, and insert it between the anchor bolt and the drum, with at least 1/2 inch of rope extending beyond the anchor bolt. tighten the anchor bolt firmly until it flattens the wire rope against the drum. Figure 5 Installing the Wire Rope - Models 462 and 4622PB rotate handle CLOCKWISE to wind wire rope onto the drum install wire rope OVERWOUND on drum as shown or winch and brake will not operate properly tighten anchor bolt

page 8 Owner's Manual for Thern Worm Gear Hand Winches 1.4.3 for models 472, 4722pb, 482 and 482b anchor the wire rope using the recessed anchor. See Figure 6. a b pass the end of the wire rope through the anchor hole, until at least 1/2 inch of rope extends out the other side. tighten the set screw until it flattens the wire rope against the anchor hole. Use enough force to drive the point of the set screw securely into the wire rope. 1.4.4 turn the handle clockwise to wind wire rope onto the drum. If wire rope unwinds from the drum when the handle is rotated clockwise, the wire rope is installed incorrectly. Install the wire rope correctly before continuing. See Figure 5 and 6. 1.4.5 wind four full wraps of wire rope onto the drum by operating the winch while holding the wire rope taught. These wraps serve as anchor wraps and must remain on the drum at all times. Figure 6 Installing the Wire Rope - Models 472, 4722PB, 482 and 48B rotate handle CLOCKWISE to wind wire rope onto the drum install wire rope OVERWOUND on drum as shown or winch and brake will not operate properly tighten set screw

Owner's Manual for Thern Worm Gear Hand Winches page 9 2.1 General Theory of Operation Important! Limit nonuniform winding by keeping tension on the wire rope and by maintaining the proper fleet angle. It is your responsibility to detect and account for different factors affecting the condition and performance of the equipment. 2.1.1 The pull required to move the load must not exceed the load rating of the winch. Consider the total force required to move the load, not the weight of the load. 2.1.2 This equipment can develop forces that will exceed the load rating. It is the responsibility of the equipment user to limit the size of the load. Inspect the equipment regularly for damage according to the instructions contained in this manual. 2.1.3 Use a disc brake on all hand winches used to lift loads or pull loads on an incline. Although a new winch may appear to hold the load in place, this characteristic will diminish with use. Do not depend on worm gearing to hold the load in place. 2.1.4 Performance ratings of the equipment are affected by the amount of wire rope wound on the drum, the way in which it is wound, and the way the winch is used. a b c Drum capacity depends on how tightly and evenly the wire rope is wound on the drum. Actual drum capacities are usually 25-30% less than values shown in performance Tables, due to loose winding and overlapping. Force required to lift the load increases with each additional layer of wire rope wound onto the drum. Load rating represents the maximum pull that can be placed on new equipment. Load ratings are assigned values for specific amounts of load travel or wire rope accumulation. The load rating decreases as layers of wire rope accumulate on the drum. 2.1.5 Duty ratings refer to the type of use the equipment is subject to. Consider the following when determining duty rating. a b c d Environment: harsh environments include hot, cold, dirty, wet, corrosive, or explosive surroundings. Protect the equipment from harsh environments when possible. maintenance: poor maintenance, meaning poor cleaning, lubrication, or inspection, leads to poor operation and possible damage of the equipment. Minimize poor maintenance by carefully following the instructions contained in this manual. loading: severe loading includes shock loading and moving loads that exceed the load rating of the equipment. Avoid shock loads, and do not exceed the load rating of the equipment. Frequency of Operation: frequent or lengthy operations increase wear and shorten the life span of gears, bearings, and other components. Increase maintenance of the equipment if used in frequent operations. Contact the factory for more information.

page 10 Owner's Manual for Thern Worm Gear Hand Winches 2.2 Breaking-In the Winch 2.2.1 Break-in occurs during the first 10 hours of normal operation. During break-in, mating surfaces become polished, and clearances increase. This is desired for efficient operation of bearings and gears. 2.2.2 Inspect the winch following break-in according to the Instructions for Periodic Inspection. 2.3 Preparing for Operation Important! When determining whether the load will exceed the load rating, consider the total force required to move the load. 2.3.1 Consider the operation. Do not begin until you are sure you can perform the entire operation without hazard. 2.3.2 Inspect all components of the system. a Inspect the winch and other equipment according to the Instructions for Frequent Inspection. b c Operators must be in good health, alert, thoroughly trained in operating the equipment, and properly clothed (hard hat, safety shoes and safety glasses, no loose clothing). The load must be clear of other objects and free to move. Make sure the load will not tip, spin, roll away, or in any way move uncontrollably. 2.3.3 Know your load and make sure you do not exceed the load rating of the winch or any other equipment in the system.

Owner's Manual for Thern Worm Gear Hand Winches page 11 2.4 Attaching the Load Figure 7 Attaching Load latch closed tight against hook Do not wrap the wire rope around the load. This damages the wire rope and could cause the load to escape. Use a sling or other approved lifting device. 2.4.1 Clear objects from the path of the load so you can move it freely and observe it at all times during the operation. 2.4.2 Attach the load using a nylon sling, or other approved lifting device. Follow the recommendations of the sling manufacturer. sling seated in saddle of hook a b Seat the sling in the saddle of the hook with the hook latch completely closed. See Figure 7. Center the load on the hook so it will remain balanced and not tip or rotate to one side. 2.5 Moving the Load Important! Obey a stop signal from anyone. Maintain tension on the wire rope to keep it tightly and evenly wound on the drum. If the winch and load are not visible during the entire operation, get help from another person. Appoint a supervisor if more than one person is involved in the operation. This will reduce confusion and increase safety. When lifting a load, use a tag line to keep the load from swinging or twisting, while keeping yourself away from the load. Remove the winch handle when the winch is not in use, to help avoid unauthorized use. 2.5.1 Move the load slowly and smoothly, only a small distance at first. Make sure the load is balanced and securely attached before continuing. 2.5.2 Turn the handle clockwise to wind wire rope onto the drum. If wire rope unwinds from the drum when the handle is rotated clockwise, the wire rope is installed incorrectly. Install the wire rope correctly before continuing. See Figures 5 and 6. 2.5.3 grip the handle tightly at all times during operation. If you release the handle, the load may backdrive, causing the handle to spin. Do not try to stop a spinning handle, step clear until spinning stops. 2.5.4 observe the wire rope as it winds onto the drum. If it becomes loose, uneven, or overlapped, stop the operation and rewind the wire rope before continuing. Continued operation with overlapped or uneven wire rope can damage the wire rope and shorten its life. 2.5.5 observe the gearbox during operation for signs of overheating. Frequent overheating may be a sign of damage, or may indicate the need for a larger winch. a b watch for smoke, the smell of burnt lubricant, and other signs of overheating. Use a thermocouple or other device to monitor gearbox temperature. stop the operation if the gearbox overheats, and allow the winch to cool. Continued operation may cause damage.

page 12 Owner's Manual for Thern Worm Gear Hand Winches 3.1 Cleaning the Winch Important! Increase the frequency of maintenance procedures if the winch is: Operated for long periods. Used to pull heavy loads. Operated in wet, dirty, hot, or cold surroundings. Clean the winch to remove dirt and help prevent rust and corrosion. 3.1.1 Clean the winch every six months or whenever it is dirty. a b c Wipe all equipment to remove dirt and grease. Leave a light film of oil on all surfaces to protect them against rust and corrosion. Wipe off excessive amounts of oil to avoid the accumulation of dirt. 3.1.2 Remove all unnecessary objects from the area surrounding the winch. Figure 8 Lubricating the Outboard Bearing and Brake lubricate the disc brake with 1 to 2 drops of SAE 30 non-detergent oil lubricate the outboard bearing with 2 to 3 drops of SAE 30 non-detergent oil Figure 9 Installing the Breather Plug breather plug breather plug breather plug level check plug level check plug level check plug drain plug or grease fitting. drain plug or grease fitting drain plug or grease fitting seal with plug after to prevent leaks. floor mount wall mount ceiling mount

Owner's Manual for Thern Worm Gear Hand Winches page 13 3.2 Lubricating the Winch Important! Do not leave plug holes in the gearbox open. Open plug holes will allow dirt and moisture to contaminate the lubrication. Make sure lubricant has a temperature rating appropriate for the ambient temperatures of the operation. Use grease rated for worm gearing operation. Grease will separate and liquefy with heat or non-use over periods of time. Do not over lubricate the brake bushings. Over lubricating may cause oil to leak onto the friction discs, which may damage the friction discs or result in poor operation of the disc brake. Make sure the breather plug is clean and open to vent heat and pressure. Poor ventilation may cause overheating and result in equipment damage. Breather plugs are required for the PB series. Refer to parts list for your model. Fill the gearbox to the proper level without overfilling. Too much or too little lubricant will cause overheating and result in equipment damage. The winch is shipped without lubricant in the gearbox. Lubricate the winch properly to help protect it from wear and rust. Read the following instructions carefully. 3.2.1 Change gearbox oil after the first 40 hours of operation. 3.2.2 check oil level and fill, if needed, before every operation, and every 10 hours during operation. Fill the gearbox through the breather plug hole until the lubricant reaches the level check plug. Use 90 weight gear oil. See Figure 9. a b check oil level by removing the check level plug. Fill the gearbox through the breather plug hole until the oil reaches the level check plug. re-install check level plug when gearbox is filled. 3.2.3 change gearbox oil every 6 to 12 months, or when it is dirty or otherwise contaminated. Remove the drain plug to drain oil from the gearbox. See Figure 9. 3.2.4 grease can be used as an alternate gearbox lubricant. It is not necessary to replace the grease after being placed in service. 3.2.5 check grease level every 6 months of operation and fill, if needed. Fill the gearbox through the lowest plug location or drain plug hole until the lubricant reaches the level check plug. Use grease rated for worm gearing operation such as a Alco Metalube or Mobil products. a b check grease level by removing the check level plug, clean plug opening and pump grease into fitting to verify grease is filled to the gear case check level plug. re-install check level plug when gearbox is filled. 3.2.6 lubricate the disc brake at least every 6 months. Place 1 to 2 drops of SAE 30 non-detergent oil into the hole in the brake housing marked "oil", and turn the brake several times to allow the oil to penetrate. See Figure 8. 3.2.7 Lubricate the wire rope and other equipment by following the manufacturer s recommendations.

page 14 Owner's Manual for Thern Worm Gear Hand Winches 3.3 Inspecting the Equipment Important! Start an inspection program as soon as you put the winch into use. Appoint a qualified person to be responsible for regularly inspecting the equipment. Keep written records of inspection. This allows comparison with comments from previous inspections so you can see changes in condition or performance. Perform frequent inspections: Before each operation. Every 3 hours during operation. Whenever you notice signs of damage or poor operation. Frequent Wire Rope Inspection: Use ASME B30.7 as a guideline for rope inspection, replacement and maintenance. Check the wire rope, end connections and end fittings for corrosion kinking, bending, crushing, birdcaging or other signs of damage. Check the number, distribution and type of visible broken wires. See paragraph 3.3.4 b and Figure 10. Check the wire rope for reduction of rope diameter from loss of core support, or wear of outside wires. See Figure 12. Take extra care when inspecting sections of rapid deterioration such as sections in contact with saddles, sheaves, repetitive pickup points, crossover points and end connections. Do not use damaged or malfunctioning equipment. Place an OUT OF ORDER sign on the winch. Do not use the winch until the sign is removed by a qualified maintenance person who has completely corrected the problem. Inspect the winch to detect signs of damage or poor operation before they become hazardous. See Table 1 - Inspection Checklist. 3.3.1 Consult applicable codes and regulations for specific rules on inspecting the winch and other equipment. 3.3.2 Consult manufacturer s recommendations for information on inspecting the wire rope and other equipment. 3.3.3 Instructions for Frequent Inspection a b Visually inspect the entire winch and all other equipment involved in the operation. Check all equipment for cracks, dents, bending, rust, wear, corrosion and other damage. Make sure the wire rope is installed correctly and anchored securely to the drum. Make sure the winch and brake are properly lubricated. Check the gearbox for signs of leakage and make sure it is filled with the proper lubricant. Make sure the breather plug is clean, open and installed properly. See Figure 1. Make sure fastener holding the handle in place is tight. See Figure 3 or 4. Make sure mounting fasteners are tightened securely. Make sure the foundation is in good condition, and capable of supporting the winch and its load under all load conditions. Test winch performance by moving a load equal to the load rating. Listen for unusual noises, and look for signs of damage as you operate the winch. Make sure the wire rope winds evenly and tightly onto the drum. If it is loose or uneven, rewind it before continuing. Make sure the handle rotates freely in both directions. Make sure the load moves smoothly without hesitation or strain. On models equipped with a brake, make sure the disc brake ratchet pawl clicks firmly as the brake handle is turned clockwise. On models equipped with a brake, check the brake. Raise the load, then lower it and stop it a few feet off the ground. If the load continues to coast or creep under normal operating conditions, the friction discs may be worn and in need of replacement. Contact the factory. Completely correct all problems before continuing. Use the Troubleshooting Chart to help determine the cause of certain problems. See Table 2.

Owner's Manual for Thern Worm Gear Hand Winches page 15 Perform periodic inspections: Every 6 months. Whenever you return the winch to service from storage. Whenever you notice damage or poor operation in a frequent inspection. Whenever you have, or think you may have, overloaded or shock loaded the winch. Figure 10 Broken Wires wire one lay 3.3.4 Instructions for Periodic Inspection, see Table 1. a Visually inspect the winch and all other equipment. Disassembly may be required in order to properly inspect individual components. Contact factory for assembly/disassembly instructions. Disassembly of the winch or brake before contacting Thern, Inc. voids all warranties. Check the finish for wear, flaking, or other damage. Check all equipment, including wire rope for cracks, dents, bending, rust, wear, corrosion and other damage. If the winch was overloaded, or if you notice cracks and other signs of overloading and damage promptly remove equipment from use and have it repaired or replaced. Do not continue to use damaged or overloaded equipment or wire rope. Check all fasteners for stripped threads, wear, bending, and other damage. Check the foundation for cracks, corrosion, and other damage. Check the gearbox for signs of leakage. Make sure the breather is clean, open and installed correctly. Make sure all labels and plates are readable, firmly attached, free of damage and clean. Replacements are available from the factory. strand Wire rope assembly must be replaced if more than 6 wires are broken in one lay, or if more than 3 wires are broken in one strand in one lay. Figure 11 Load Hook Inspection twist throat opening thickness The wire rope assembly must be replaced if the throat opening is 15% wider than nominal, if the thickness is 10% less than nominal, or if the hook is twisted 10 or more. b c drain a small amount of oil from the gearbox into a clean container. Check the oil for dirt, metal particles, water, and other signs of contamination. Completely drain the gearbox if oil is contaminated. Make sure the gearbox is properly lubricated. See section 3.2 - Lubricating the Winch. inspect the wire rope according to the wire rope manufacturer's recommendations, or follow accepted industry standards for wire rope inspection. Always wear protective clothing when handling wire rope. Check the entire length of wire rope for bent wires, crushed areas, broken or cut wires, corrosion, and other damage. Carefully inspect areas that pass over sheaves or through roller guides. Note the location and concentration of broken wires. Replace wire rope if more than 6 wires are broken in one lay, or more than 3 wires are broken in one strand in one lay. See Figure 10. Make sure the load hook or other device is securely attached to the wire rope, and the wire rope where it is attached is not frayed, corroded, broken, or otherwise damaged. Measure the throat opening, thickness, and twist of the hook. Replace the hook if it shows signs of damage. See Figure 11. Make sure hook latch opens without binding and closes when released. Check the anchor holes in the drum flange for signs of wear or distortion.

page 16 Owner's Manual for Thern Worm Gear Hand Winches Figure 12 Rope Diameter correct diameter incorrect The wire rope assembly must be replaced if the diameter measures less than the minimum diameter at any point. wire rope diameter minimum diameter 1/8 in 7/64 in (.1094 in) 3/16 in 11/64 in (.1719 in) 1/4 in 15/64 in (.2344 in) 5/16 in 19/64 in (.2969 in) d e f f g Move the drum with your hands. Check for excessive movement indicating worn or loose gears, bearings, or shafts. Slight end play in the drive shaft is normal. Excessive movement is caused by overloading or overheating, and it is a sign that your application may require a larger winch. Contact factory for assembly/disassembly instructions. Disassembly of the gearbox before contacting Thern, Inc. voids all warranties. Place enough weight to keep the wire rope straight and tightly drawn. Measure the diameter of the wire rope, especially in areas where wear is noticeable. Replace the wire rope if the diameter measures below the minimum diameter at any point. See Figure 12. inspect the foundation and rigging Check mounting fasteners for stripped threads, wear, and other damage. Check the foundation for cracks, corrosion, and other damage. Fasten the winch securely to the foundation. Test winch performance by operating the winch with a load equal to the load rating. Listen for unusual noises, and look for signs of damage as you operate the winch. Make sure the wire rope winds evenly and tightly onto the drum. If it is loose or uneven, rewind it before continuing. Observe the rotating drum, look for signs of loose or misaligned bearings. Make sure the handle rotates freely in both directions. Make sure the load moves smoothly, without hesitation or strain. On models equipped with a brake, make sure the disc brake ratchet pawl clicks firmly as the brake handle is turned clockwise. On models equipped with a brake, check the brake. Raise the load, then lower it and stop it a few feet off the ground. If the load continues to coast or creep, the friction discs may be worn and in need of replacement. Completely correct all problems before continuing. Use the troubleshooting chart to help determine the cause of certain problems. See Table 2.

Owner's Manual for Thern Worm Gear Hand Winches page 17 Table 1 Inspection Checklist checked boxes indicate damage or problem in need of repair damages problems general finish weathered, flaking, otherwise damaged winch jerks or hesitates during operation parts cracked, bent, rusted, worn, otherwise damaged unusual noises, other signs of malfunction fasteners stripped threads, bent, worn, otherwise damaged loose, not tightened to proper torque worm gearbox gears, bearings, or shafts loose, otherwise damaged not filled with proper lubricant oil leakage lubricant contaminated brake assembly brake corroded, cracked, worn, otherwise damaged brake does not operate properly drum anchor hole or bolt worn, distorted, otherwise damaged excessive movement or backlash wire rope bent, crushed, otherwise damaged wire rope loosely or unevenly wound broken wires, see Figure 10 replace if more than 6 wires in one lay, number per strand = or 3 wires in one strand in one lay, are broken number per lay = diameter reduced, see Figure 12 replace if diameter is excessively worn diameter = end connections corroded, rusted, worn, otherwise damaged not securely attached load hook twisted, bent, worn, otherwise damaged, see Figure 11 hook latch fails to close when released replace if twist is 10 degrees or more twist = replace if throat width is 15% larger than nominal throat width = replace if thickness is 10% less than nominal thickness = labels and plates dirty, illegible, otherwise damaged loosely attached or missing comments: authorized signature: date

page 18 Owner's Manual for Thern Worm Gear Hand Winches Table 2 Troubleshooting Chart Contact the factory for detailed instructions if you are required to disassemble the winch or brake for any reason. Disassembly of the winch or brake before contacting Thern, Inc. voids all warranties. problem cause correction handle turns, drum doesn't turn loose or broken spring pins...inspect winch and brake, repair as necessary loose, stripped or broken gears or keys...inspect gears and repair as necessary handle turns hard or not at all winch overheated...allow to cool load too heavy...lighten load gearbox contaminated with dirt or debris...inspect and relubricate as necessary spring pins loose or broken on winch or brake...inspect winch and brake, repair as necessary disc brake damaged or locked...inspect brake, repair as necessary gears or keys broken or locked...inspect and repair as necessary outboard bearing broken or seized...inspect and repair as necessary brake does not operate properly friction discs worn or damaged...inspect and replace as necessary friction discs damaged from over lubrication...inspect and replace as necessary disc brake ratchet pawl damaged...inspect and repair as necessary oil leakage damaged gasket cement...inspect and replace as necessary cracked or damaged gearbox...inspect and repair as necessary excessive end play on drive shaft thrust washer or bearing worn out...inspect and replace as necessary excessively worn gears...inspect and repair as necessary excessively worn gears or bearings load too heavy...lighten load (excessive backlash) poor lubrication of gears or bearings...inspect and relubricate as necessary overheating operated too long without rest...allow to cool load too heavy...lighten load poor lubrication...inspect and lubricate as necessary vent plug clogged or damaged...clean or replace vent plug as needed outboard bearing seized up...inspect and replace as necessary unusual noises high pitched squeak poor lubrication...inspect and relubricate as necessary grinding noise contaminated lubrication...clean and relubricate winch dirt in brake or winch gears...inspect and clean as necessary broken gears or outboard bearing...inspect and replace as necessary rattling noise loose bolts, set screws or other fasteners...tighten all bolts and other fasteners uneven clicking noise in brake broken gear tooth in brake...inspect and repair as necessary weak clicking noise in brake spring or ratchet pawl dirty or damaged...inspect and clean or repair as necessary worn brake ratchet pawl, gear, or spring...inspect and replace as necessary no clicking noise in brake ratchet incorrectly installed...disassemble and install correctly ratchet pawl damaged or worn excessively...inspect and replace as necessary heavy thump during operation contaminants in oil...flush gearbox and relubricate winch loose setscrews or keys in gears...inspect and repair as necessary thrust washer or bearing defective...inspect and replace as necessary outboard bearing defective...inspect and replace as necessary

Owner's Manual for Thern Worm Gear Hand Winches page 19 3.4 Repairing the Winch Important! It is your responsibility to determine when to replace parts. When considering whether to continue using a part or to replace it, remember that replacing it is the best way to avoid further equipment damage. Replace all spring pins and retaining rings when you disassemble the winch or brake for repair or inspection. During reassembly, use Loctite 598 Ultra Black to create a seal between the two halves of the gearbox. Contact the factory for detailed instructions. Disassembly of the gearbox before contacting Thern, Inc. voids all warranties. Appoint a qualified person to be responsible for all repairs to the equipment. 3.4.1 Get factory authorization for all repairs. Unauthorized repairs will void the warranty, and may lead to damage or failure of the winch. 3.4.2 Replace damaged or poorly operating parts with Thern repair parts. 3.4.3 Refinish areas where the paint is worn or flaking. A good finish helps to protect against corrosion and weather damage. a b c Remove the finish from damaged areas, down to the bare metal. Clean the area thoroughly. Repaint with a high quality primer and finishing coat. 3.4.4 To order repair parts, contact your local dealer. Include the following information when ordering: model number serial number (or code number) part number date purchased, and from whom description of what happened, or what is wrong your name and return address

page 20 Owner's Manual for Thern Worm Gear Hand Winches 4.1 Transporting the Winch Important! Keep a record of what you ship, and when you send it. 4.1.1 drain oil from the gearbox. 4.1.2 remove the breather plug and install a sealed oil plug to prevent the loss of lubrication during shipment. 4.1.3 Pack the winch in an upright position for transport, using the original packaging materials, if possible. a b c fasten the winch to a wooden base using the lag bolts, to keep it from moving during transport. seal the winch in plastic with a desiccant to help protect it from rust, corrosion, and other damage. construction wooden sides and top to enclose the winch in a solid protective crate. d pack loose parts in a small box or ship separately. 4.1.4 Inspect the winch according to section 3.3 - Inspecting the Equipment before installing it in a new location. 4.2 Storing the Winch 4.2.1 lubricate the winch as necessary, and make sure the breather plug is clean and properly installed. Add a rust preventative for long term storage. 4.2.2 Seal the winch in plastic with a desiccant to help protect it from rust, corrosion, and other damage. 4.2.3 Store the winch upright, in a cool clean place away from corrosive chemicals and moisture. 4.2.4 Rotate the drum periodically to keep bearing and gear surfaces from becoming lacquered. 4.2.5 Inspect the winch according to section 3.3 - Inspecting the Equipment before installing it in a new location. 4.2.6 lubricate the winch properly prior to operation. See section 3.2 - Lubricating the Winch.

Owner's Manual for Thern Worm Gear Hand Winches page 21 Worm Gear Hand Winches - Configurations and Performance Characteristics 3 load rating (lb) wire drum capacity (ft) 1 force 2 approx. model 4 1st mid full rope 1st mid full gear to lift number description layer drum drum dia. (in) layer drum drum ratio 1000 lb 462 1000 lb enclosed gearing 1000 700 500 1/8 7 61 140 15:1 34 lb (recommended for pulling only) 3/16 4 28 61 4622PB 1000 lb enclosed gearing 1000 700 500 1/8 7 61 140 15:1 26 lb with brake (for lifting) 3/16 4 28 61 472 2000 lb enclosed gearing 2000 1700 1300 3/16 15 65 140 24:1 24 lb (recommended for pulling only) 1/4 11 35 77 5/16 8 23 52 4722PB 2000 lb enclosed gearing 2000 1700 1300 3/16 15 65 140 24:1 24 lb with brake (for lifting) 1/4 11 35 77 5/16 8 23 52 482 4000 lb enclosed gearing 4000 3300 2500 1/4 23 140 300 26:1 31 lb (recommended for pulling only) 5/16 18 91 200 3/8 14 65 140 482B 4000 lb enclosed gearing 4000 3300 2500 1/4 23 140 300 26:1 31 lb with brake (for lifting) 5/16 18 91 200 3/8 14 65 140 Please contact factory or nearest Thern Distributor for firm, fixed price and delivery. 1 Actual drum capacities may be 25-30% less, due to nonuniform winding. Wire rope tension will also affect drum capacity. 2 Approximate handle force required to lift 1000 lb with an empty drum, and maximum handle length. 3 Performance Characteristics are for standard products referred to in this manual. Non-standard products may vary from the original design. Contact Thern, Inc. for this information. 4 Models ending with a V have frames rotated 90 degrees. Performance characteristics for vertical models are the same as with standard models.

page 22 Owner's Manual for Thern Worm Gear Hand Winches

Owner's Manual for Thern Worm Gear Hand Winches page 23

page 24 Owner's Manual for Thern Worm Gear Hand Winches

Owner's Manual for Thern Worm Gear Hand Winches page 25

page 26 Owner's Manual for Thern Worm Gear Hand Winches

Owner's Manual for Thern Worm Gear Hand Winches page 27

page 28 Owner's Manual for Thern Worm Gear Hand Winches

Owner's Manual for Thern Worm Gear Hand Winches page 29

page 30 Owner's Manual for Thern Worm Gear Hand Winches 1 2 3 4 5 8 6 7 9 10

Owner's Manual for Thern Worm Gear Hand Winches page 31 Brake Assembly for Model 462PB-P3 SC7154 item description part number qty. 1 BRAKE COVER A1105 1 2 BRAKE HOUSING/BEARING ASSEMBLY C5256 1 3 RETAINING RING 1.750 SST A3883 1 4 1 DRIVE ASSEMBLY B4210 1 5 CAPSCREW HEXHD.375-16NC X 1.500 SST A3884 1 6 TORSION SPRING SST A1842 1 7 RATCHET PAWL A1103 1 8 HEX JAM NUT.375-16NC SST A3330 1 9 LOCK WASHER HELSPR.375 X.683 X.094 SST A3357 1 10 SPACER.391 X.500 X.675 A1104 1 1 Brake Drive Assembly ordered complete.

page 32 Owner's Manual for Thern Worm Gear Hand Winches

Owner's Manual for Thern Worm Gear Hand Winches page 33

page 34 Owner's Manual for Thern Worm Gear Hand Winches

Owner's Manual for Thern Worm Gear Hand Winches page 35

Thern, Incorporated 5712 Industrial Park Road Winona, MN 55987 PH 507-454-2996 FAX 507-454-5282 EMAIL: info@thern.com www.thern.com Thern Europe Windmolen 22 7609 NN Almelo Netherlands PH +31-548-659-052 EMAIL: europe@therneurope.eu